Eating utensil with inwardly curving scores

ABSTRACT

A deformable sheet defines a handle and an operational element in which one or more scores, which may be straight, curved, or a combination of straight and curved, are cooperatively provided to enable deformation of the handle portion to convert the operational element into a strong, sturdy, and functional implement sufficient to meet the required application. When curved scores are present, they may be concave (outwardly curving) or convex (inwardly curving) with respect to the longitudinal midline of the operational element.

CROSS REFERENCE TO RELATED APPLICATIONS

This patent application is a divisional of U.S. patent application Ser. No. 14/449,151 filed Aug. 1, 2014 (attorney docket ECOT 7028 US), which is a continuation of U.S. patent application Ser. No. 13/357,557 filed Jan. 24, 2012 (attorney docket ECOT 7006 US), which claims the benefit of U.S. provisional patent application 61/435,975 filed Jan. 25, 2011 (attorney docket ECOT 7005 PR); all of these previous patent applications are hereby incorporated by reference in their entireties into the present patent application.

BACKGROUND OF THE INVENTION

The invention relates generally to utensils used for foodstuff, and more particularly to user-constructible utensils used for eating, tasting, scooping, spreading, stirring, food processing/consuming, and the like, even more particularly to more environmentally sustainable single-use implementations of such products.

Sustainability, recyclability, composability are becoming increasingly important to retailers and consumers. However, not everyone uses the terms correctly—marketers sometimes use these indiscriminately and vaguely, often to the frustration of environmentally and socially conscious manufacturers, retailers, and users who desire more accuracy. Increasingly standards for sustainability are being developed and used to help retailers and consumers avoid “green washing” for the products that they buy and use.

For true ecological friendliness, materials and products meet specific, ever-evolving standards and requirements. The “green” world employs a special lexicon, particularly for words such as degradable, biodegradable, recyclable, sustainable, and compostable.

Degradable plastics are oil based and break down through chemical reactions rather than the activity of micro-organisms, so they can degrade in an anaerobic environment into water, CO₂, biomass, and trace elements. For example, the term “biodegradable” by itself does not mean much when biodegradable plastics and some types of biodegradable spoons include products that may take hundreds to thousands of years to degrade. Since “biodegradable” specifies NO time limits, for the purposes of composting and sustainability “biodegradable” is a meaningless term.

To be considered compostable, plastic material must break down within 180 days in a commercial compost facility. Biodegradable plastic has no time limit According to the American Society for Testing & Materials (e.g., ASTM D6400—2004 “Standard Specification for Compostable Plastics,” ASTM International, West Conshohocken, Pa., 2003, DOI: 10.1520/D6400—04, hereby expressly incorporated by reference hereto in its entirety for all purposes), for plastic to be considered as compostable, it must be able to break down into carbon dioxide, water, and biomass at the same rate as paper. It also needs to look like compost, should not produce any toxic material, and should be able to support plant life. Compostable items are made from plant materials such as corn, potato, cellulose, soy, sugar, and the like.

Another important ASTM standard is ASTM D6868—2011 “Standard Specification for Labeling of End Items that Incorporate Plastics and Polymers as Coatings or Additives with Paper and Other Substrates Designed to be Aerobically Composted in Municipal or Industrial Facilities,” ASTM International, West Conshohocken, Pa., 2003, DOI: 10.1520/D6868-11, also hereby expressly incorporated by reference hereto in its entirety for all purposes. This specification establishes the requirements for labeling of materials and products (including packaging), wherein a biodegradable plastic film or coating is attached (either through lamination or extrusion directly onto the paper) to compostable substrates and the entire product or package is designed to be composted in municipal and industrial aerobic composting facilities within 180 days.

The term “compostable” until recently was subject to some ambiguity. Certifications and representations of compostability most often reference commercial/municipal composting facilities that precisely control the environment (e.g., temperature) and microbes (e.g., periodic infusion of appropriate quantities of the appropriate microbes). Few bio-based utensils are certified compostable, and most include varying amounts of plant based starch and petroleum and take over the required 180 days or more to compost under the best of conditions. Home composting is rarely an option for these materials. Some “biodegradable” products like Taterware may take years—compost facilities either disallow all bioplastic utensils or pick them out of the compost at the end of the composting process.

Consumers have become increasingly skeptical of certain claims as to the various “green” attributes of various manufacturers and products since the introduction of “biodegradable plastics” in the late 1980s. Although touted as “environmentally friendly,” many so-called biodegradable plastic products did not compost as implied. And yet manufacturers of these products were able to make claims of biodegradability because no scientifically based definitions, test methods and standards existed. Promulgation, adoption, and use of the ASTM specifications, definitions, and tests mentioned above provide a standard by which products and materials may be evaluated. To this end, there are organizations that provide certification of conformance to one or more of these standards as appropriate. For example, the Biodegradable Products Institute, 331 West 57th Street, Suite 415, New York, N.Y. 10019 has created a “compostable logo” which is designed to help remove some of the confusion for consumers. The Compostable logo builds credibility and recognition for products that meet the ASTM D6400 and/or D6868 standards so consumers, composters, regulators, and others can be assured that the product will compost as expected.

As consumers, composters, waste scavengers, regulators, and others continue to develop the technologies and processes for efficiently handling and sorting consumer waste, consumers and businesses (collectively purchasers) are on the front line and make important decisions. The decisions include selection, use, and disposal of products. Selection is important, based upon a purchaser's understanding the degradability of the product and, as noted above, can be improved by certifications informing a purchaser of the attributes of a product. Additionally, based upon experience and history that the purchaser has with particular products, the purchaser may be influenced towards selection or use. This is important with utensils designed for foodstuffs—how the utensil feels in the mouth of the user is important. Coatings, sharp edges, dimensions, sturdiness, and the like all play a part in selection and use.

After selection and use, the user decides on, or initiates/influences, post-use handling. It is not always clear to the user whether a product is recyclable, compostable, or should be included as trash. Users are often confronted with a multitude of bins with disposal options. For some products, it is problematic to select the wrong receptacle. And the propriety is not just a simple matter of knowing the characteristics of the product—one sometimes needs to know the specifics of the processing used by the disposal/recycling/scavenging entity to match a product to the right process capabilities of recycler/scavenger. This can be overwhelming to a user and can produce undesirable outcomes for the intended “green” behavior. For example, many petroleum-based utensils are recyclable, and most bio-based plastics are NOT recyclable. Most users cannot readily distinguish one composition from another to allow them to properly manage the product, even if they were current as to the recycling capabilities of the local processor.

As varying compositions of consumer-products are introduced, the user becomes increasingly confused as to which product they want to process is recyclable and how to quickly and error-free sort the various products. Some “green” conferences have recycling advisors stationed at waste collecting areas to help educate users.

There are many instances where single-use products are currently used for tasting and consuming foodstuffs. Mostly these products are made from a plastic or a bio-material that is not, or is insufficiently, compostable and easily bio-degradable. These products typically come preformed into the recommended configuration for use by the user.

To compound the problem, there are many venues in which utensils are single-use (e.g., foodstuff tasting/dispensing utensils or single-serving disposable utensils). Not only is the sorting/processing problem multiplied by the sheer volume of these products used world-wide, they also use up too many resources. This is because these products also have the further undesirable characteristic of attempting to emulate conventional multi-use utensils in their construction and arrangement, which results in poor packing density. Manufacturers, distributors, and retailers are increasingly concerned about cube utilization (amount of product that can be shipped/stored in a specific cubic volume). The less efficient the cube utilization, particularly as compared to alternative products, the more costly it becomes to ship and warehouse.

It is not always the case that a utensil design scales well as seen in many “mini” tasting spoons that yield a bowl that is often too small and shallow for properly supporting, dispensing, and consuming adequate serving sizes of a range of foodstuff. Both the retailer and the end-user can become frustrated by this. Sometimes the design is further altered after scaling, which results in more material and often worse cube utilization. Not only can these products be inefficient, such products often take up an unnecessarily large amount of space in the preformed configurations while being inefficient and costing more. It is understandable, as preformed configurations in consumer-familiar designs are believed to maximize strength while minimizing user complexities.

Compounding the problem further, bioplastics use more material in their construction because they do not have the same material properties (e.g., tensile strength of bio-material versus stainless steel versus conventional petroleum-based plastic). There are many disadvantages to conventional tasting/single-use utensils, particularly to those attempting to be truly environmentally-friendly.

Currently, there are several “green” factors that can be independently evaluated, which include: recyclable, renewable, compostable, sustainable, and usage of material efficiency and cube utilization efficiency for volume and weight. A product and processes that measure favorably against these factors while being friendly, convenient, effective, and efficient for the retailer, consumer and waste processor is preferred. What is needed is an eco-friendly, user-constructible, single-use utensil that meets or exceeds performance of conventional preformed utensils.

BRIEF SUMMARY OF THE INVENTION

The present invention includes a series of embodiments directed to tasting, stirring, spreading, and otherwise processing/consuming foodstuff by a user. A deformable sheet defines a handle and an operational element in which one or more scores, both straight and curved, are cooperatively provided on the sheet. The one or more scores enable deformation of the handle and/or operational element(s) to convert the structure into a strong, sturdy, and functional implement sufficient to meet the required application. In the preferred embodiment, the unconstructed utensil is provided on a planar sheet made of the requisite material (i.e., an appropriately green/sustainable material) that may be processed to enhance function (e.g., coated with environmentally appropriate material) to resist premature degradation during use (e.g., a moisture-barrier), or it may be manufactured of a moisture-barrier material (e.g., calcium carbonate). Collectively, a coating, or inherent characteristic or other moisture protection system is referred to as moisture-barrier property. Thus, quantities of the unconstructed material achieve a far greater packing density as compared to pre-constructed utensils, which saves money on shipping and storage because of the smaller cube size. For many applications, the handle and operational elements are minimalist in material cost while maximizing structural strength and user-experience consistent with the intended use, all the while having a smaller carbon footprint.

The handle, typically with a curved score that defines a folding axis, is operated by bringing portions closer together out of the plane (e.g., folding or otherwise deforming) the handle along the one or more handle scores. This folding induces a responsive distortion/deformation of the operational element to create the desired functional element. The curved score(s), in cooperation with the structural organization and composition, produce a constructed utensil that meets or exceeds performance of conventional preformed disposable/single-use utensils. This provides a superior option over conventional constructed utensils, because the user gains the advantage of an improved single-use application while the utensil is eco-friendly, as it has a minimalist design that is effective and capable of being made compostable and/or recyclable with recyclable, sustainable, renewable resources. These constructible utensils may be particularly configured for specific applications, including tasting, stirring, spreading, consuming harder/firmer foodstuffs, “fork-like” utensil, and the like.

Manufacturers have an option of configuring the base material, the periphery boundary, the placement and orientation of scores, and any coating to customize the final design in a wide variety of ways. As further explained herein, the user-constructible utensils include tasters, spreaders, stirrers that can have appropriately shaped handles and operational elements (e.g., bowls for a tasting spoon) that have the desired capacity, shape, and mouth-feel. Some bowls may have a deep configuration for more capacity, while others may be shallower and sturdier to serve dense/hard foodstuff (e.g., ice cream). The fundamental teachings herein are adaptable to a wide variety of user-constructible utensils for a wide variety of tasks. In some cases, the utensil doubles as a dispensing mechanism, in lieu of a cup, which is particularly important for applications that use a utensil along with a cup and/or plate/napkin, cracker, or the like, providing valuable cost-savings.

In some embodiments, such as a dispensing and tasting implement at a food show or the like, the base material and scores are arranged and configured so that a deformed handle (e.g., folded) maintains a sufficiently useful fold after being released from the folder to retain the desired configuration of the operational end. For example for a tasting spoon, several utensils may be configured, including folding the handle to produce the bowl. The folded utensils are set on a work surface and a product is placed into each of the bowls. Consumers may simply pick up a utensil and sample the product without any other apparatus. This allows for one-handed sampling, as opposed to cup and spoon, which is ideal for consumers having their hands full with products, information, containers, children, and the like. In many of the preferred embodiments, lateral edges of the planar apparatus are folded up to produce a handle and bowl, often leaving a planar medial portion of the handle and bowl that provide a stable platform for adding, dispensing, and presenting the product to the prospective consumers. Most tasting spoons could not be arrayed and used in this fashion as they are not large enough or stable enough and do not have the upward-extending handle portions to allow them to be easily grasped. In this way, packing density for dispensing and presenting is improved and retailers/users may select from a middle of the array with greatly reduced risk of touching or otherwise contaminating foodstuff in other utensils.

Particularly for those applications that include a disposable plate, cup, napkin for dispensing and a utensil to consume, the versatility of the implementations of the present invention in combining these functions further saves costs and reduces environmental impact in the pre-consumer and post-consumer costs of such scenarios.

As noted above, many existing single use solutions attempt to emulate conventional utensils. While this is desirable to simplify training and use of the utensils, the products are often wasteful of material (and in some cases extra unneeded material results in the material/product taking up excessive space, which further adds to costs in transportation and storage and is “anti-green”), particularly for applications where the utensil may be used for a few seconds. Considering that some current utensils are used for just a few seconds and may exist in landfills for centuries, points out one of the many problems addressed and mitigated by embodiments of the present invention.

The preferred implementations of the present invention provide a greatly reduced carbon footprint due to several factors, including use of a new minimalist design (rather than scaling of previous utensils) that both uses less material and reduces unnecessary material and use of environmentally friendly materials. This is true even in cases where the material is misprocessed by the consumer after use. For example, if a compostable EcoTensil® brand utensil ends up in a landfill it will have an increased chance to be partially-to-substantially degraded by the time it gets to the landfill where under normal conditions it would not degrade. (Modem landfill designs attempt to minimize any degradation of all materials by removing oxygen and other requirements for biodegradation/composting). Because the product has minimal material use and quickly degrades, the product lends itself to interstitial location among the nooks and crannies of other more rigid elements of the landfill, which effectively removes its contribution to the landfill volume.

Reduction in material used in the designs helps to maximize an amount of pre-disposal degradation that occurs, which is advantageous no matter whether the consumer selected the correct disposal option. The advantages of minimal construction are magnified when also considering the production, shipment, storage, use, and disposal volumes. The reduced eco-footprint appears all along the lifespan of the product, and savings and advantages are compounded when considering the entire lifecycle.

A constructible utensil, such as for a taster for example, includes a deformable generally planar rigid paperboard sheet defining a body, the body including a handle element having a fold axis and a bowl element coupled to the handle element wherein the handle element is generally elongate and rectilinear and includes a length generally parallel to the fold axis that is at least two times greater than a width generally perpendicular to the fold axis; a first curved score disposed on the body and extending from a first point on the bowl element proximate a first edge of the bowl element to a second point on the handle element proximate the fold axis; and a second curved score disposed on the body and extending from a third point on the bowl element proximate a second edge of the bowl element towards the second point; wherein the scores are generally concave (outwardly curving) with respect to the fold axis; and wherein the body is configured with an arrangement of the scores such that a folding of the body about the fold axis introduces a bowl in the bowl element by distortion of the bowl element along the curved scores.

A constructible utensil, such as for a stirrer for example, includes a deformable generally planar rigid sheet material defining a body, the body including a handle element having a fold axis and a bowl element coupled to the handle element at a transition area wherein the handle element is generally elongate and includes a length generally parallel to the fold axis that is at least ten times greater than a first width generally perpendicular to the fold axis; a first score disposed on the body and extending from a first point on the bowl element to a second point on the handle element proximate the fold axis and crossing the transition area; and a second score disposed on the body and extending from a third point towards the second point, wherein the third point is disposed on the bowl element; wherein the scores are curved and generally concave (outwardly curving) with respect to the fold axis and generally symmetrical about the fold axis; wherein the body is configured with arrangement of the scores such that a folding of the body about the fold axis introduces a bowl in the bowl element.

A constructible utensil, such as for a spreader for example, includes a deformable generally planar rigid paperboard sheet defining a body, the body including a handle element having a fold path and a spreader element coupled to the handle element wherein the spreader element is generally asymmetrically elongate and includes a first lateral edge generally straight and parallel to the fold path and a second lateral edge generally convexly curved with respect to the fold path and converging to the first lateral edge; a first score disposed on the body and extending from a first point on the spreader element to a second point on the handle element proximate the fold path; and a second score disposed on the body and extending from a third point towards the second point; wherein the body is configured with arrangement of the scores such that a folding of the body about the fold path introduces a bowl in the spreader element.

A constructible utensil includes a deformable generally planar rigid paperboard sheet defining a generally elongate and rectilinear body having a long axis extending from a proximal end to a distal end and a short axis generally perpendicular to the long axis with the body including a fold axis extending along the long axis and the body including a length generally parallel to the fold axis that is at least two times greater than a width generally parallel to the short axis; a first curved score disposed on the body and convex with respect to the fold axis, the first curved score extending from a first point on the body near a first lateral edge of the body at the distal end of the body to a second point on the body proximate the fold axis, wherein the first point is greater than 75% of the length from the proximal end and wherein the second point within 33% of the length from the proximal end; and a second curved score, symmetric about the fold axis to the first curved score and disposed on the body, the second curved score extending from a third point on the body near a second lateral edge of the body at the distal end to the second point; wherein the body is configured with arrangement of the scores such that a folding of the body about the fold axis introduces a bowl in the body at the distal end by distortion in the body along the scores.

A method of manufacturing a constructible utensil includes a) forming a generally elongate and rectilinear body from a deformable generally planar rigid paperboard sheet, the body having a long axis extending from a proximal end to a distal end and a short axis generally perpendicular to the long axis with the body including a fold axis extending along the long axis and the body, including a length generally parallel to the fold axis that is at least two times greater than a width generally parallel to the short axis; b) disposing a first curved score on the body, the first curved score convex with respect to the fold axis, the first curved score extending from a first point on the body near a first lateral edge of the body at the distal end of the body to a second point on the body proximate the fold axis, wherein the first point is greater than 75% of the length from the proximal end and wherein the second point within 33% of the length from the proximal end; and c) disposing a second curved score, symmetric about the fold axis to the first curved score, on the body, the second curved score extending from a third point on the body near a second lateral edge of the body at the distal end to the second point; wherein the body is configured with arrangement of the scores such that a folding of the body about the fold axis introduces a bowl in the body at the distal end by distortion in the body along the scores.

A method of constructing a utensil includes a) folding a generally elongate and rectilinear body about a fold axis, the body constructed from a deformable generally planar rigid paperboard sheet, the body having a long axis extending from a proximal end to a distal end and a short axis generally perpendicular to the long axis with the body including the fold axis extending along the long axis and the body including a length generally parallel to the fold axis that is at least two times greater than a width generally parallel to the short axis and the body including a pair of curved scores symmetrically disposed on the body, the pair of curved scores convex with respect to the fold axis, the curved scores extending from a pair of points on the body near opposing lateral edges of the body at the distal end of the body and each converging to a convergence point on the body proximate the fold axis, wherein the pair of points are greater than 75% of the length from the proximal end and wherein the convergence point is within 33% of the length from the proximal end; and b) inducing a bowl in the distal end responsive to the folding step a) by distorting the body along the pair of scores as the body is folded.

A system for serving a foodstuff includes a worksurface; and a plurality of user-constructible utensils constructed into a plurality of shape-retaining utensils with each the shape-retaining utensil including a bowl-element supporting a portion of the foodstuff and having a pair of lateral edges folded upwards and retained folded without adhesive due to a configuration of construction materials used in a manufacture of the plurality of user-constructible utensils and wherein the plurality of constructed utensils are arrayed on the worksurface with the upward pair of lateral edges useable as a handle to remove a corresponding utensil and foodstuff from the worksurface.

Other advantages of the present invention will be seen by a review of the present written description and drawings, all of which show various embodiments of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a plan view of a stirrer embodiment of a constructible utensil;

FIG. 2 illustrates a plan view of a taster embodiment of a constructible utensil;

FIG. 3a through FIG. 3c each illustrates a plan view of one of three spreader embodiments of a constructible utensil;

FIG. 4 illustrates a plan view of a stiff/rigid taster embodiment of a constructible utensil;

FIG. 5 illustrates a plan view of an alternate embodiment of a constructible utensil with convex (inwardly curving) scores; and

FIG. 6 through FIG. 10 illustrate various views of the taster embodiment shown in FIG. 2 constructed into a utensil; specifically:

FIG. 6 illustrates a perspective view from an elevated frontal view;

FIG. 7 illustrates a top plan view;

FIG. 8 illustrates a side plan view;

FIG. 9 illustrates a front plan view;

FIG. 10 illustrates a rear plan view;

FIG. 11 illustrates a plan view of an alternate taster embodiment of a constructible utensil different from the taster shown in FIG. 2;

FIG. 11a illustrates an end view of a folded disposition of the constructible utensil illustrated in FIG. 11; and

FIG. 12 illustrates a foodstuff serving system.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Embodiments of the present invention provide a system and method for a user-constructible single-use utensil that meets or exceeds performance of conventional preformed utensils. It is a feature of preferred embodiments of the present invention to be material efficient, in terms of nature and type of material as well as minimal volume sufficient for the anticipated use. Most preferably, these embodiments are made from renewable and sustainable material and are compostable. The following description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements. Various modifications to the preferred embodiments and the generic principles and features described herein will be readily apparent to those skilled in the art. Thus, the present invention is not intended to be limited to the embodiments shown but is to be accorded the widest scope consistent with the principles and features described herein.

It should be noted that the figures include specific shapes, paths, and arrangements of scores used to facilitate formation of three dimensional bowls as a part of a body is folded. The scores have been illustrated to accurately present representative suitable score paths for the particular utensil type and application, particularly with respect to location, arrangement, and placement.

In some cases, a preferred embodiment includes environmentally friendly materials which often include paper and paper-like substances. For a utensil, it is the case that the foodstuff may have a significant moisture content. To enhance longevity in terms of preserving structural integrity and strength over the serving/portion size, moisture resistance is important in some implementations. Such utensils may be processed to enhance function (e.g., coated with environmentally appropriate material) to resist premature degradation during use (e.g., a moisture-barrier) or they may be manufactured of a moisture-barrier material (e.g., calcium carbonate or the like). Collectively, a coating, or inherent characteristic or other moisture protection system is referred to as moisture-barrier property.

Some preferred embodiments include a paperboard sheet material. In some of the descriptions, there are certain score lines that are specifically set forth to be close to, but spaced away from, an edge of a body or body element of a constructible utensil. For some materials, these scores break down fiber used in the body and could increase moisture absorption. Spacing a terminating end of these score lines away from the physical edge improves moisture absorption resistance.

FIG. 1 illustrates a plan view of a stirrer 100. Stirrer 100 includes a long thin handle 105 with a center score 110 extending along a longitudinal axis, about which stirrer 100 is generally symmetric. An operational end 115 includes a wide curved section 120 joined to handle 105 at a junction 125 (section 120 wider than handle 105). A pair of curved scores 130 extend from edges of the operational element (i.e., the wide curved stirring end) and converge towards center score 110 and meet generally at junction 125. Deforming (e.g., folding) handle 105 along center score 110 by bringing the edges together through lifting the edges out of a plane containing stirrer 100 in an unfolded mode induces a deformation of the section to create a small generally bowl-shaped end.

In a preferred embodiment, stirrer 100 is characterized in having a body that is much longer than it is wide (e.g., >1Ox longer than wide) with a bowl element joined to a handle at a transition zone (e.g. junction 125). The handle is generally rectilinear, which includes rectangular structures that may include generally rectangular structures with rounded corners. In some cases, one end or the other may be wider or narrower than an intermediate portion of the handle. In some cases, one end is wider (or narrower) than the other end or the intermediate portion. Ovals, oblongs, and the like are additionally included within the scope of “rectilinear”, based upon context and overall impression and relationship of components. Curved scores 130 are concave (outwardly curving) with respect to a fold axis extending along a body of stirrer 100, with the fold axis aligned with center score 110. A curvature of curved scores 130 is determined by a width and length of a bowl element (e.g., section 120). Some stirrers may have smaller and larger bowls as suited for the particular application.

FIG. 2 illustrates a plan view of a taster 200. Taster 200 includes a generally “bullet” shaped perimeter 205 having a longitudinal axis 210 about which taster 200 is generally symmetric. Perimeter 205 is about 1.25 inches wide and about 3.125 inches long (the “bullet” shaped perimeter including a generally rectangular body that is about 1.25 inches×about 2.5 inches and a semi-disk at one end of the rectangle having a radius of about 0.625 inch). A handle portion 215 is joined to a functional end 220 with handle portion 215 including a short handle score 225 extending along the longitudinal axis and joining a pair of curved scores 230 extending from lateral edges of functional end 220 located at a distal end (e.g., opposite of handle portion 215 at a proximal end). In some implementations, handle score 225 may be omitted, its function provided by an extension of one or more curved scores 230 extending towards the proximal end from the distal end. Folding/deforming the proximal end along the handle score (or handle score substitute) induces the deformation of functional end 220 about the one or more curved scores to create a three-dimensional structure (generally described as arched or bowl-shaped), which adds strength/rigidity and function, such as retaining low-viscosity foodstuff.

Tasters are generally small, and taster 200 is particularly configured to reduce material use while providing efficient operation. A size and shape of a bowl formed in taster 200 at the distal end is determined, again, by the arrangement of the scores with respect to the body and its structures. For example, in the preferred embodiment, the scores are close to lateral edges of the body near the distal end (without reaching the edge to improve mouth feel by reducing sharp edges) and converge to a central fold axis near the proximal end and produce the desired bowl shape shown in FIG. 6 through FIG. 10. The scores are gentle and concave (outwardly curving) with respect to the fold axis and curve over almost the entire length of the rectilinear body and do not meet until very close to the edge. For purposes of this application in the context of a taster, the scores converge within 33% of the length of the body element from the handle end and most preferably within 10% of the length from the handle end. At the other end, the scores reach near the lateral edges at points greater than 50% of the length and most preferably at points greater than 75%.

Included with taster 200 are informational indicia (e.g., specifically positioned dots) that identify a preferred location for squeezing/deforming handle portion 215. (E.g., bend to touch dots, which recreates the desired deformation in the handle to help optimize formation of the functional element.) Preferably, these indicia are placed near where the scores converge, in this case, towards the proximal end of the body, so that the body gradually distorts along scores generally over the entire length.

In some embodiments, it will be desirable to provide some type of mechanism to maintain the lateral edges of the body (e.g., near the indicia) in a generally folded arrangement to preserve a desired minimum capacity/shape to the formed bowl (and to maintain those lateral edges extending upwards to be easily grasped, to permit taster 200 to be picked up from a work surface, especially with the bowl shape retained). The material selection of the body, and the depth and nature of the formation of the scores, are ways to provide for a retaining force resisting unfolding when a folding force is removed. In other embodiments, some type of tacky adhesive or interconnecting tabs may be used to hold the lateral edges together and the body in the folded mode.

FIG. 3a through FIG. 3c each illustrates a plan view of one of three different spreaders 300 (including a first spreader 305, a second spreader 310, and a third spreader 315). Spreaders 300 are constructed similarly to stirrer 100 and taster 200, with the additional element that one or more structures (e.g., handle, functional element, and one or more of the handle score(s) and/or curved score(s) may be asymmetric and/or an operational axis (a fold line/path defined by the handle score) may not be straight or define a symmetric longitudinal axis and have a generally asymmetric curved profile particularly at the functional end for “spreading” a foodstuff (Similarly to non-constructible foodstuff spreaders, one edge may be generally straight and an opposing “spreading” edge curved. Spreaders 300 of the preferred embodiment include a longer curved score extending towards the straight edge and a shorter curved score extending towards the curved spreading edge, with one or more shorter curved scores sometimes not crossing a junction between the handle portion and the functional end.) Some embodiments include a score for folding a spreader element that is generally perpendicular to a longitudinal axis defined by a handle portion.

Spreader 305 includes a handle portion 320, typically with one or more handle scores 325, that interact with one or more curved score(s) 330, with one or more of the curved scores 330 (like in other implementations) crossing over a junction between a functional element 335 at a distal end and handle portion 320 at a proximal end).

Spreader 310 includes a handle portion 340, typically with one or more handle scores 345, that interact with one or more curved score(s) 350, with one or more of the curved scores 350 (like in other implementations) crossing over a junction between a functional element 355 at a distal end and handle portion 340 at a proximal end). Spreader 310 includes a score 360 for folding that is generally perpendicular to a longitudinal axis defined by handle portion 340 that permits functional element 355 to fold and stow away proximate and parallel to handle portion 340. One or more curved scores 350 preferably cross over score 360 to add strength and rigidity to functional element 355 when unfolded and handle portion 340 folded/deformed along handle scores 345.

Spreader 315 includes a handle portion 365, typically with one or more handle scores 370, that interact with one or more curved score(s) 375, with one or more of the curved scores 375 (like in other implementations) crossing over a junction between a functional element 380 at a distal end and handle portion 365 at a proximal end). Similarly to spreader 310, spreader 315 includes a score 385 for folding that is generally perpendicular to a longitudinal axis defined by handle portion 365 that permits functional element 380 to fold and stow away proximate and parallel to handle portion 365. One or more curved scores 375 preferably cross over score 385 to add strength and rigidity to functional element 380 when unfolded and handle portion 365 folded/deformed along handle scores 370. Spreader 315 is particularly suited for use as, or in cooperation with, a lid of a container of spreadable foodstuff or the like. When functional element is folded relative to handle portion 365, handle portion 365 has a perimeter generally matching a mouth and/or a lid of the container.

As noted above for some spreaders 300, some implementations include provision of one or more of the curved scores being completely constrained to the handle portion while one or more curved score(s) cross the junction and have components on both the handle and the functional element. Some spreaders 300 include a generally perpendicular score proximate the junction between the handle and functional element to permit the functional element to be folded to shorten the unconstructed length. In these embodiments, the functional end is unfolded and then the handle is folded/deformed along the one or more curved scores. Again, dots or other indicia help the user informing the handle fold/deformation that induces a preferred deformation about the curved scores.

FIG. 4 illustrates a plan view of a stiff/rigid taster 400, such as may be appropriate for ice cream scoops and the like. Taster 400, similar to the products and implementations described herein, particularly to taster 200 described above, includes a variation from the others. Namely, for “hard” ice cream, an even stronger functional element is desired. Thus, elements of the functional element, and cooperating scores are adapted to strengthen the functional element.

Taster 400 includes a blunted generally “bullet” shaped perimeter 405 having a longitudinal axis 410 about which taster 400 is generally symmetric. A handle portion 415 is joined to a functional end 420 with handle portion 415 including an extended handle score 425 extending along the longitudinal axis and joining a pair of curved scores 430 extending from lateral edges of functional end 420 located at a distal end (e.g., opposite of handle portion 415 at a proximal end). In some implementations, handle score 425 may be omitted, its function provided by an extension of one or more curved scores 430 extending towards the proximal end from the distal end back to a near end of handle portion 415. Folding/deforming the proximal end along the handle score (or handle score substitute) induces the deformation of functional end 420 about the one or more curved scores to create a three-dimensional structure (generally described as arched or bowl-shaped), which adds strength/rigidity and function.

Included with taster 400 are informational indicia (e.g., specifically positioned dots) that identify a preferred location for squeezing/deforming handle portion 415. (E.g., bend to touch dots, which recreate the desired deformation in the handle to help optimize formation of the functional element.)

Blunting the perimeter somewhat (as compared to taster 200, such as by using a more elliptical path for the end as opposed to a circular path), and advancing convergence point (and the dots) towards the distal end to increase a rate of curvature, improves the strength and rigidity of functional end 420. This has an effect of enhancing and strengthening the deformation about the curved score. In a preferred embodiment, this “advanced” convergence point is located on the body at a point between 33% and 66% of the length away from an end of the handle. Most preferably the convergence point is near a midpoint of the handle.

FIG. 5 illustrates a plan view of an alternate embodiment of a constructible utensil 500. As may be an alternative to a “spork” or the like. Utensil 500, similar to the products and implementations described herein, particularly to taster 400 described above, includes a variation from the others. Namely, for certain foodstuffs, a generally “pronged” or “tined” functional element having sufficient strength is desired. Thus, elements of the functional element, and cooperating inwardly curved scores 535, are adapted to strengthen the functional element, which is provided with prongs/tines.

Utensil 500 includes a blunted generally “bullet” shaped perimeter 505 with a notch 510 provided in a blunted end 515 to provide a pair of prongs/tines. Utensil 500 includes a longitudinal axis 520 about which utensil 500 is generally symmetric. A handle portion 525 is joined to blunted end 515 with handle portion 525 including an axial handle score 530 that, in a preferred embodiment, bifurcates along axis 520 into a pair of inwardly curved (convex) scores 535. Curved scores 535, generally symmetric about axis 520, extend from handle score 530 to near a tip of each prong/tine of blunted end 515. Utensil 500 includes a prong score 540 extending from notch 510 along said axis 520 back towards handle portion 525. In some implementations, handle score 530 may be omitted, its function when desired provided by an extension of one or more inwardly curved scores 535 extending towards the proximal end from the distal end back to near an end of handle portion 525. Folding/deforming the proximal end along handle score 530 (or handle score substitute) induces a pair of deformations of blunted end 515 about each of inwardly curved scores 535 centered on prong score 540 to create a pair of three-dimensional prong/tine-line structures (each generally described as arched) which adds strength/rigidity and function to each prong/tine.

Utensil 500, like the other constructible utensils described herein, may include informational indicia (e.g., specifically positioned dots) that identify a preferred location for squeezing/deforming handle portion 525. (E.g., bend to touch dots, which recreate the desired deformation in the handle to help optimize formation of the prongs/tines.)

Variations include terminating the scores, particularly ends of the curved scores 535 towards the lateral edges of the functional element, away from the actual physical edge. This has an effect of making the transition of the deformed functional element with less “sharp” edges which has a better mouth experience. Additionally, the radius of curvature of the curved scores 535 helps define a degree of induced strength post-deformation, and the location where a user actually grips and folds the handle portion has an effect on the constructed utensil.

For elements like the stirrer, generally a uniform deformation may be implemented along the length of the handle. For the other implementations, the place where the user grips and squeezes the handle typically is the place where the handle is closest together, which affects the induced deformation of the curved scores. Having indicia to help locate and position this grip helps to ensure a better result for the consumer to help optimize the constructed utensil for its intended use.

The constructible utensils described share a number of features in addition to those previously described. For example, the preferred constructible utensils (e.g., stirrer 100, taster 200, spreaders 300, taster 400, and utensil 500) are stamped from a sheet of rigid stock material preferably made from renewable easily biodegradable materials (e.g., FSC certified sources). Preferably, the stock materials of the preferred embodiments have a thickness ranging between about 14-18 point caliper, though other thicknesses may be appropriate, depending upon design considerations. Scores and any desired indicia may be added before, during, or after stamping. Preferably, any inks used for the indicia are non-toxic vegetable-based dyes. Some of the embodiments benefit from a coating to improve mouth-feel and/or provide a moisture-barrier to extend use for the constructible utensils, such as those expected to be used for minutes instead of seconds.

Another shared feature is that the folding of a body element along a fold axis or a fold line induces formation of a three-dimensional structure referred to herein as a bowl, bowl, element or the like. The shape, size, and capacity of this bowl is determined by the size and shape of a perimeter of the body, the path and arrangement of the scores disposed on the body, and the location along the body where the body is folded, particularly how close to the bowl that lateral edges of the body are folded together.

For example, FIG. 6 through FIG. 10 illustrate various views of the taster embodiment shown in FIG. 2 constructed into a utensil, such as for tasting. These views show representative elements of a preferred embodiment for the bowl. FIG. 6 illustrates a perspective view from an elevated frontal view, FIG. 7 illustrates a top plan view, FIG. 8 illustrates a side plan view, FIG. 9 illustrates a front plan view, and FIG. 10 illustrates a rear plan view. Folding along the fold axis/fold line induces a curving distortion of the body about the curved scores, creating the bowl at a distal end opposite of a proximal end where lateral edges of the body are folded up out of a plane and brought together.

As described above, coatings are important not only for resisting soaking of the base structure, but also to improve the user-experience with the constructed utensils when put into the mouth. This is more important for the “spoon” type utensils, where a user may lick the utensil. Many users disapprove and are unaccepting of utensils that taste like “cardboard”—which can diminish the user's experience with tasting/consuming their foodstuff. The coating, like the structural features described herein to help ensure a narrow, smooth (non-sharp) functional end, greatly improve the mouth feel and therefore promote the experience and enhance the acceptance of constructible utensils. While many different compostable, non-toxic coatings may be used depending upon the application and context of the application, preferably the coating conforms to the incorporated ASTM specification for compostability. Depending upon the application, the coating is configured for user experience including moisture-resistance and mouth-feel/palatability. In some cases, the coating is used to improve fiber strength for upcycling pulp quality.

Another important aspect of the constructible utensils described herein is that they make exemplary security utensils for use in jails, detention centers, prisons, security centers, and the like. The utensils may be made strong and rigid enough for a desired length of time for the purpose of consumption of the foodstuff but lack sufficient tensile/compressive strength to be used as a weapon that can cause injury.

The constructible utensils described herein may be made of a wide-variety of materials. An advantage for such utensils is that they are easily constructed of materials used in other products made by a vendor. For example, Starbucks® has a program to enhance its ecological image and reduce its footprint resulting from the cups, napkins, and other elements, like stirrers. In one initiative, Starbucks plans to recycle its annual three billion paper cups and convert them into napkins. Stirrer 100 may be made from cup stock as well and be used in this program to recycle the stirrers resulting in multiple financial and environmental benefits.

Stirrer 100 is particularly advantaged as a constructible utensil used in an dining establishment like Starbucks and the like. Stirrer 100 is not a simple stirrer like a straw or straight stick commonly used in the “coffee” beverage context. Stirrer 100 includes not only a stirrer feature, but it may be a scoop (for sweetener, condiments, and the like) and a spoon for sampling whipped cream or other tasty froth or beverage. The sturdiness and improved mouth-feel (e.g., coated, smooth, narrow, and no sharp edges) of stirrer 100 contribute to its multi-faceted usefulness, making it more than a simple stirrer. That, and it stores flat and is able to be compostable, improve its lifetime impact by being a superior product even in disposal.

Regarding strength and rigidity, such as for the strengthened taster 400 and utensil 500, as noted herein the degree of curvature, paths, and positions where curves are initiated and whether the scores actually terminate at an edge or spaced away from an edge provide a constructible utensil designer with many options for adapting the constructed utensil to the intended application. Folding creates, along with the inherent resistance of the base material, a balanced tension/compression loading with the scores and other design features to create desired strength and sturdiness. Generally, as the radius of curvature for the curved scores portions decreases, the more curvy and the stronger is the resulting utensil element. Taster 400 includes tighter curves as compared to taster 200 for example. Too curvy can diminish mouth feel, especially if sharp edges result. Folding the handle closer to a curve enhances the strength and rigidity as well.

Some embodiments of the constructible utensils include a dynamic feature. For example, with taster 400 it is possible to squeeze the handle tightly, particularly tight close to the curves of the curved scores improves “scooping” while the handle may be relaxed, allowing the functional element to soften and flatten for an improved tasting/consuming configuration. The user can alternate between squeezing for scooping and relaxing for tasting/consuming in this way by using the dynamic configuration capabilities of certain of the embodiments described herein.

Spreaders 300, particularly the versions adapted to be used with a container or other dispenser, advantageously fold and provide a way for the functional spreading element to be folded and protected to maintain desired levels of cleanliness and sanitariness.

As discussed herein, preferred embodiments of the present invention greatly improve upon cube utilization than other food demonstration products. Table I below includes representative comparative cube utilization data among different types of products, with ECOTASTER being an implementation of apparatus shown in FIG. 2 herein.

TABLE I Cube Utilization CUBE/5000 units Weight/5000 units Type (ft³) (pounds) ECOTASTER .25 8.8 Plastic Tasters .73 13.3 Plastic Forks 3 60 Plastic Spoons 2.5 48 2 oz. plastic cups 2.6 32 Paper baking cups 1.3 32 Paper plates 2 15 Biodegradable tasters 1.37 20

It is easy to see that in every particular, the ECOTASTER is significantly better in every respect, which is enormous when considering that hundreds of millions of these types of products are used worldwide each year. The combination of a minimalist utilitarian design that maximizes the number of devices from a sheet (which is another way of measuring waste/unit) and placement and arrangement of scores adds superior function and use. Some implementations may further improve on material use for certain applications, such as by narrowing the “waist” (e.g., a medial portion near a transition from the handle to the operational element). While it may not improve the number of units/sheet, in some cases it removes some of the weight and may further improve packing densities in transit and while stored.

FIG. 11 illustrates a plan view of an alternate taster embodiment of a constructible utensil 1100 different from the taster shown in FIG. 2. Utensil 1100 is different in that a body 1105 is relatively shortened as compared to perimeter 205 shown in FIG. 2. As a consequence, curved scores 230 do not meet together along fold axis 210, and a separation 1110 exists between them at an edge of the handle. A first handle edge 1115 and a second handle edge 1115 are formed on opposite sides of separation 1110. FIG. 11a illustrates an end view 1120 highlighting a significance of this construction when utensil 1100 is folded. A triangle is formed at an end of utensil 1100 (as looking toward the bowl element), which can further strengthen utensil 1100, particularly against lateral (e.g., side-to-side) movement, when folded along fold axis 210.

FIG. 12 illustrates a foodstuff serving system 1200. Foodstuff serving system 1200 includes a worksurface 1205 upon which an array of preconstructed constructible utensils are disposed and preloaded with a foodstuff (e.g., represented by a mini-carrot in FIG. 12) in the bowl element. As discussed herein, a preferred embodiment in some implementations of a constructible utensil of the present invention includes configuration of the sheet material and score lines, so that lateral edges of handle portions of a constructed utensil resist unfolding once folded. This configuration and construction helps to maintain the bowl shape in the bowl element, and allows a relatively high capacity bowl to remain formed when the constructed utensil is set down upon worksurface 1205. Thus, loading of the foodstuff into the bowl of the pre-constructed and arrayed utensil allows a person to access and consume a sample with a single hand. It stores and serves the foodstuff conveniently and efficiently.

The preferred embodiments use sustainable tree-based wood fibers due to improved material properties. In some applications, and as additional materials are developed, other materials (such as shorter fibers from other plants or mineral-based substrates) may be used in lieu of tree-based wood fibers. Additionally, the preferred embodiments include implementations that include multiple curved scores, including multiple curved scores that “bend” inwardly towards each other. Some implementations may include other configurations, including a single curved implementation that produces a bowl when folded along this score.

In the description herein, numerous specific details are provided, such as examples of components and/or methods, to provide a thorough understanding of embodiments of the present invention. One skilled in the relevant art will recognize, however, that an embodiment of the invention can be practiced without one or more of the specific details, or with other apparatus, systems, assemblies, methods, components, materials, parts, and/or the like. In other instances, well-known structures, materials, or operations are not specifically shown or described in detail to avoid obscuring aspects of embodiments of the present invention.

Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant, both in relation to the other endpoint, and independently of the other endpoint.

Reference throughout this specification to “one embodiment”, “an embodiment”, or “a specific embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention and not necessarily in all embodiments. Thus, respective appearances of the phrases “in one embodiment”, “in an embodiment”, or “in a specific embodiment” in various places throughout this specification are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, or characteristics of any specific embodiment of the present invention may be combined in any suitable manner with one or more other embodiments. It is to be understood that other variations and modifications of the embodiments of the present invention described and illustrated herein are possible in light of the teachings herein and are to be considered as part of the spirit and scope of the present invention.

The foregoing description of illustrated embodiments of the present invention, including what is described in the Abstract, is not intended to be exhaustive or to limit the invention to the precise forms disclosed herein. While specific embodiments of, and examples for, the invention are described herein for illustrative purposes only, various equivalent modifications are possible within the spirit and scope of the present invention, as those skilled in the relevant art will recognize and appreciate. As indicated, these modifications may be made to the present invention in light of the foregoing description of illustrated embodiments of the present invention and are to be included within the spirit and scope of the present invention.

Thus, while the present invention has been described herein with reference to particular embodiments thereof, a latitude of modification, various changes and substitutions are intended in the foregoing disclosures, and it will be appreciated that in some instances some features of embodiments of the invention will be employed without a corresponding use of other features without departing from the scope and spirit of the invention as set forth. Therefore, many modifications may be made to adapt a particular situation or material to the essential scope and spirit of the present invention. It is intended that the invention not be limited to the particular terms used in following claims and/or to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include any and all embodiments and equivalents falling within the scope of the appended claims. Thus, the scope of the invention is to be determined solely by the appended claims. 

1. A planar utensil element fabricated of an elongated foldable material, comprising: a pair of generally symmetric scores, elongated with respect to a longitudinal midline of the planar utensil element, each of said generally symmetric scores forming a convex shape with respect to the longitudinal midline; wherein folding the planar utensil element about the longitudinal midline forms a usable utensil having a handle portion and a bowl portion.
 2. The planar utensil element of claim 1 further comprising a handle score generally disposed along the longitudinal midline in the handle portion, said handle score originating at an open end of the handle portion and terminating at a termination point in an interior region of the planar utensil element; wherein said handle score facilitates formation of the handle portion when said planar utensil element is folded about said longitudinal midline.
 3. The planar utensil element of claim 2 wherein each of said generally symmetric scores originates near the termination point of said handle score.
 4. The planar utensil element of claim 1 wherein each of said generally symmetric scores terminates at an open edge of the bowl portion.
 5. The planar utensil element of claim 1 wherein each of said generally symmetric scores terminates at a point spaced apart from an open edge of the bowl portion.
 6. The planar utensil element of claim 1 further comprising a notch in a terminating open end of said bowl portion.
 7. The planar utensil element of claim 1 wherein the utensil is folded about said longitudinal midline to form two halves comprising a desired shape of the bowl portion.
 8. The planar utensil element of claim 7 wherein the two halves are held together in the handle portion with a tacky adhesive.
 9. The planar utensil element of claim 7 wherein the two halves are held together in the handle portion with interconnecting tabs. 